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Technical and economical experience with large ORC systems, 2015-11-06 © 2015 Company 2
There exist a significant potential in industry sectors worldwide
to improve energy efficiencies and valorize waste heat streams
Fig: US industries; manufacturing sector waste heat Inventory (list not exhaustive)
(source: ICF International study 2015 4))
• Largest potential is within Petroleum & coal products; Majority of waste heat
stream is on temperatures above 230°C
• The 4 top potential industries have a significant waste heat streams with
temperatures above 230°C
• Waste heat valorization potential in Cement as part of “Non-Metallic Mineral
Products” will be presented in more details
Technical and economical experience with large ORC systems, 2015-11-06 © 2015 Company 4
Energy Flow Diagram of a cement plant clinker burning kiln
Thermal Energy Input & Waste Heat Streams
210 kWh/tcl Thermal Energy Input: 780 kWh / tcem
Kiln Exit Gas @ 290- 400 °C Electrical Energy Input: 110 kWh / tcem
23%
55% 2%
Clinker Formation
Clinker Sensible Heat
Technical and economical experience with large ORC systems, 2015-11-06 © 2015 Company
5
Cement kiln Waste Heat to Power (WHP) Systems mostly use
Water-Steam-Rankine Cycle (WSRC). -- For temperatures < 300°C
Organic-Rankine Cycle (ORC) is the better option.
• Momentary ~ 900 WHP system are running worldwide (highest number in China)
• Majority of systems using steam turbines (WSRC) at temperatures > 350°C
• Average yield of WHRP in cement is ~ 30-40 kWhel/tcl
• Less than 10 WHP system using ORC concept with the objective to use low
temperature waste heat streams
• Two heat-exchangers
designed for high dust
load (cleaning system)
• Two intermediate heat
transfer loops
(either thermal oil or
pressured water)
• ORC cycle with
recuperator
(hydrocarbon, silicone
or refrigerator fluid)
• Air or water (evaporation)
cooled condenser
© 2015 Company 6
In the field of Waste Heat to Power, Holcim gained experiences from
numerous commercial operating and research projects
(since 2008 Holcim build more than 35 WHP plants)
Chekka (Lebanon)
Mid- and low-temp
(from Diesel Generator 16 MWel) Gagal / Rabryiawas (India)
2.1 WSRC + 0.9 ORC MWel, 2013 mid-temp: ~ 380°C
4.3 MWe, WSRC, 2013
6.0 MWel WRSC, 2015
WHR systems running (3 + 30)
Research
Commercial Operation ORC
Commercial Operation WSRC (steam) © 2015 Company
7
In 2012 Holcim Romania commissioned the world first
ORC-WHP power plant using kiln and cooler gas streams
© 2015 Company 8
ORC-WHR power plant with 4 MWel (gross) power output
© 2015 Company
Holcim Switzerland commissioned 2013 / 2015 a “roof-top”
ORC-WHP power plant using kiln and cooler gas streams
Cement kiln WHP Preheater gas
system with two gas tie-in
heat sources: Cooler gas
• kiln exhaust gas tie-in
• cooler air
Cooler gas
ORC Flow Sheet heat-exchanger
with two gas heat-exchangers (left)
Preheater gas
ORC fluid pre-heater and evaporator (middle)
heat-exchanger
ORC turbine & generator (right bottom)
and Air cooled condenser (right top) Preheater gas
booster-fan
Air cooled
condenser
ORC fluid
Heat-exchangers
Turbine-
generator
ORC fluid
tanks
© 2015 Company 10
Untervaz WHP ORC-WHR power plant
with 2.3 MWel (gross) 1.9 MWel (net) power output
Horizontal gas-flow pre-heater Air Cooled Condenser (four modules)
HEX bare tubes with dust rapper • no water consumption; no plume
• noise issue; higher aux. consumption (4x48kW)
Technical and economical experience with large ORC systems, 2015-11-06 © 2015 Company 11
Höver cement plant extra-low heat WHP research pilot (2013)
EU FP7 program: “LOVE” project
“Low-temperature heat valorization towards electricity production”
(waste stream gas temperature < 120°C)
Fin-and-tube
heat-exchanger
(HEX1)
Condensing Unit
Packed-Column
(PCU)
Technical and economical experience with large ORC systems, 2015-11-06 © 2015 Company 13
Heat Recovery and ORC System Parameter of WHP installed
by Holcim (2008 to 2015)
Plant Type / Size Heat- Heat- ORC turbine ORC fluid Cooling
Inlet Temp Exchanger Transfer Make / Type / Evaporation-
Make / Type Coupling Stages/ Gear / temp /
Cleaning / Axe-sealing Gross Eff
Spare Cap.
Alsed; Commercial JFE Thermo-Oil Turboden Silicone-oil Wet
Romania H-cross-flow Press-Water Axial, Multi-Stg (MM) Water-
4 MWel Gearless
Hammering Serial ~ 240°C evaporation
230 / 390°C >100% reserve Oil sealing 19.3%
Untervaz; Commercial HTA Press-Water Atlas-Copco Isobutane Dry
Switzerland H-cross-flow Parallel Radial, Single-Stg = 140-160°C Air cooled
2.3 MWel Gear
Hammering ~ 16-17%
250 / 360°C 60% reserve N2 sealing
Rohhoznik; Commercial Transparent Thermo-Oil Turboden Cyclo- Wet
Slovakia V-parallel-flow Parallel Ax-Rad, Multi-Stg pentane Water-
~ 5 MWel Gearless
Hammering ~ 210°C evaporation
310 / 360°C >100% reserve Oil sealing ~ 21%
Höver; Research Armines Water Cryostar R 245fa Wet
Germany Direct- Radial, Single-Stg (R1234yf) Water-
100 kWel Gearless
condensing = 64°C !! evaporation
< 120°C self-cleaning Variable-speed 5.9-6.2 %
hermetic housing
Technical and economical experience with large ORC systems, 2015-11-06 © 2015 Company 14
Experiences made with ORC type WHP systems
Technical and economical experience with large ORC systems, 2015-11-06 © 2015 Company 15
Issues / Learnings (1)
Overall Efficiency / Complexity / Cost Driver
• Gas Heat-Exchanger (HEX) & Heat Transfer
• Proper design (cross-flow) and sufficient exchanger surface (+ 100% reserve)
• Adequate dust removal (hammering) and transportation system
• Heat Transfer Loop: Non-pressured system preferred (Thermal-oil)
• Best Option: Avoid Heat Transfer Loop (Direct heat concept)
• Turbine type
• Multi-Stage expander (to fully use available pressure level)
• Good part-load performance (WHP source vary widely – in contrast to geo-thermal plants)
• Low rotation / gearless
• Oil / liquid turbine-axe sealing (avoid addition N2 system)
• ORC fluid
• Select fluid to match temperature level (supplier-design)
• Flammable fluid (hydrocarbons) require EX-Design
• Cooling
• Water-evaporation Systems (Wet) are more effective, need less energy and are lower in cost
compared to Air Cooled Condenser - but they need water chemicals and regular care
Technical and economical experience with large ORC systems, 2015-11-06 © 2015 Company 16
Issues / Learnings (2)
Exhaust Gas Heat-Exchanger (HEX) Size & Design
• “Japanese” Design:
Thermal capacity: 9.7 MW
Exchanger Area: 4950 m2
Specific Area: 0.5 m2 / kW
• “German” Design:
Thermal capacity: 10.4 MW
Exchanger Area: 3110 m2
Area reserve: 60 %
Specific Area: 0.3 m2 / kW
Technical and economical experience with large ORC systems, 2015-11-06 © 2015 Company 17
Issues / Learnings (3)
Maximal use of available Energy
• Loss of Exergy
• Some system design results in high Exergy Loss (do not use available temperature level)
• Gas Inlet temperature is quit high but HEX heat transfer • Gas Inlet temperature is extra-low; HEX heat transfer
coefficient is low and Isobutane fluid properties do not coefficients are OK – but fluid with gliding evaporation
match very well temperature (azeotrope mixture) would be more adequate
Technical and economical experience with large ORC systems, 2015-11-06 © 2015 Company 18
Economics
• I’m an engineer:
• I want to develop solutions –
but it must be economical
Technical and economical experience with large ORC systems, 2015-11-06 © 2015 Company 19
WHP generated power has slightly lower cost compared to
“standard” Renewable Energy production cost –
– but WHP is not eligible for “RE Incentives”
Industry Investment Conditions
• WACC = 8%
• Pay-back = 10 years
Wind • Inflation = 0.5%
Wind *)
off-shore • No incentives considered
Swiss Alps
European
Solar PV EI-Industry
Germany *) power cost
WHR target
• In the near future, WHP in EI-Industry will compete with Renewable Energy
Systems, mainly Solar PV (Fraunhofer ISE)
Technical and economical experience with large ORC systems, 2015-11-06 © 2015 Company 22